Multi-Part Solid-State Tool for Lubricant-Free Alloy Deposition
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Solution Overview
Problem
Existing metal part production methods, such as forging and extrusion, require expensive components and often necessitate the use of lubricants, which can compromise material integrity and performance.
Innovation Solution
A multi-component tool for solid state manufacturing that allows for the deposition of solid materials without lubricants, utilizing high thermal conductivity materials, reversible coupling, and draft angles to facilitate material deposition and reduce sticking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional forging or extrusion processes are used to produce metal parts, then the parts can be shaped and produced, but expensive components and lubricants are required which compromise material integrity and performance
Solution Approach 1:
The tool is divided into multiple separable members (first member, second member, third member) that can be independently optimized. This segmentation allows each component to be designed for specific functions (feeding, deposition, friction) without requiring expensive integrated components, while eliminating the need for lubricants that compromise material integrity
Solution Approach 2:
A gasket is introduced as an intermediary element between tool members to provide thermal breaks. This intermediary component enables heat management without requiring expensive cooling systems or lubricants, maintaining material integrity while controlling thermal effects during the solid state manufacturing process
2Ease of operation
If lubricants are used in traditional manufacturing processes, then material can be moved and shaped, but material integrity and performance are compromised
Solution Approach 1:
The harmful element (lubricant) is completely removed from the system. Instead of using lubricants to enable material flow, the invention extracts this dependency by using friction bosses and draft angles to achieve material movement through mechanical means alone, preserving material integrity
Solution Approach 2:
Friction, which was previously a harmful force requiring lubricant mitigation, is converted into a beneficial force. Friction bosses intentionally generate friction to rotate and move solid feedstock material through the tool and onto the substrate, eliminating the need for lubricants while improving material flow control
3Reliability
If solid feedstock material is deposited without lubricants, then material integrity is improved, but material sticking to the tool surface occurs
Solution Approach 1:
Draft angles are applied to the tool channel geometry, creating asymmetric surfaces that facilitate material release. The channels are designed with tapered profiles rather than parallel walls, allowing deposited material to be easily released from the tool surface without requiring lubricants, thus maintaining material integrity
Solution Approach 2:
The friction bosses feature curved or rounded surfaces that facilitate material rotation and movement. These curved geometries help prevent material sticking by distributing contact forces and enabling smooth material flow through the tool without adhesion to tool surfaces
4Temperature
If high thermal conductivity materials are used for tool members, then heat can be managed during deposition, but thermal breaks are needed between members
Solution Approach 1:
The tool is segmented into multiple members with a gasket between them to create thermal breaks. This segmentation allows each member to be made of high thermal conductivity material for effective heat management at the deposition interface, while the gasket prevents excessive heat transfer to upstream components, managing temperature distribution without requiring complex cooling systems
Solution Approach 2:
A gasket is introduced as a thermal intermediary between tool members. This gasket provides controlled thermal resistance to create thermal breaks, enabling heat management during deposition while maintaining a relatively simple tool structure without complex cooling channels or active temperature control systems
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables consistent material performance, reduces cracking and internal voids, improves ductility, and enhances fatigue life and fracture toughness of deposited materials.
Implementation Method 1
the tool comprises a gasket between the first member and the second member, wherein the gasket is configured to provide a thermal break between the first member and the second member
Implementation Method 2
the second channel of the second member comprises a draft angle at the second outlet of the second member to permit deposition of the solid feedstock material from the second outlet onto a surface without using any lubricant on the solid feedstock material
Implementation Method 3
the first member and the second member each comprises a material with a thermal conductivity of at least 125 W/m-K
Implementation Method 4
the second member comprises at least one friction boss configured to generate friction between a face of the tool and the surface during rotation of the tool while depositing the solid feedstock material onto the surface
Data Source
AI summary
Tools for use in solid state manufacturing processes are described. Certain configurations of the tool include multiple different components that can reversibly couple to each other. The tools can be used in solid state manufacturing processes to deposit high strength alloy materials without the need to use a lubricant with the materials to be deposited.